Method of forming a reusable surgical implement

Abstract

A reusable surgical implement or template is provided that is formed of a core positioned within an enclosure. The core is formed of a suitable rigid, and optionally flexible material to enable the implant to conform to the desired use for the implement in a surgical procedure. The material forming the enclosure is also stretchable and flexible to accommodate the configuration and/or any flexing of the core, and is biologically inert to enable the implant to be sterilized after use for use in subsequent surgical procedures while protecting the material forming the core. The enclosure can be molded around the core in separate portions or components using multiple molding steps to form an enclosure with the desired attributes. The enclosure can also be preformed and the core inserted and secured within the enclosure using an adhesive to form the implement in an alternative manner.

The invention claimed is: 
     
       1. A method of forming a reusable surgical implement, the method comprising the steps of:
 a) forming a core; 
 b) forming a tubular enclosure having a pair of opposed open ends; 
 c) applying an adhesive to an exterior of the core; 
 d) inserting the core within the enclosure to form the implement; and 
 e) manipulating the enclosure and the core to remove bubbles from between the enclosure and the core, 
 
       wherein the step of manipulating the enclosure and the core comprises rolling the enclosure and core against a hard surface. 
     
     
       2. The method of  claim 1  wherein the step of forming the enclosure comprises extruding a material to form the enclosure. 
     
     
       3. The method of  claim 2  wherein the material is a silicone rubber. 
     
     
       4. The method of  claim 1  wherein the step of forming the enclosure comprises molding a material to form the enclosure. 
     
     
       5. The method of  claim 2  wherein the material is a thermoplastic elastomer. 
     
     
       6. The method of  claim 1  wherein the adhesive is a lubricating adhesive. 
     
     
       7. The method of  claim 1  wherein the step of applying the adhesive to the core comprises applying the adhesive to only a portion of the exterior of the core. 
     
     
       8. The method of  claim 1  wherein the step of inserting the core within the enclosure comprises pressing the core into one open end of the enclosure. 
     
     
       9. The method of  claim 8  further comprising the step of twisting the core concurrently with pressing the core into the open end of the enclosure. 
     
     
       10. The method of  claim 1  wherein the step of rolling the enclosure and core comprises:
 a) rolling the center of the enclosure and the core against a hard surface; and 
 b) rolling the enclosure and the core against the hard surface outwardly from the center towards the ends of the enclosure. 
 
     
     
       11. The method of  claim 1  further comprising the step of curing the adhesive between the enclosure and the core after manipulating the enclosure and the core. 
     
     
       12. The method of  claim 1  further comprising the step of forming an end cap on each end of the enclosure after inserting the core within the enclosure. 
     
     
       13. The method of  claim 12  wherein the step of forming the end cap comprises forming the open ends of the enclosure into the end caps. 
     
     
       14. The method of  claim 12  wherein the step of forming the end cap comprises placing an end cap material over the open ends of the enclosure and the ends of the core.